ION, L-Series, S-Series 1999-2005

Brake Caliper

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Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Remove the front wheel and tire assembly.
  2.  
  3. Disconnect the brake hose from the caliper and discard the 2 copper washers.
  4.  
  5. Plug the openings to prevent system contamination or excessive fluid loss.
  6.  
  7. Remove the lock pin and guide pin from the caliper.
  8.  
  9. Remove the caliper from the support, being careful not to damage the pin boots.
  10.  
  11. Remove the pin boots from the caliper support and inspect for damage.
  12.  

To install:

  1. If necessary, bottom the caliper piston by hand, or by using a C-clamp.
  2.  
  3. If removed, install the brake pads and clips to the caliper support.
  4.  
  5. Lubricate the pin boots and guide pins with silicone grease.
  6.  
  7. Install the pin boots into the caliper support, using the pin to assure that the boot passes all the way through the support.
  8.  
  9. Position the caliper onto the support and over the brake pads.
  10.  
  11. Lubricate the non-threaded portion of the guide and lock pins with silicone grease.
  12.  
  13. Install the pins through the caliper and torque to 27 ft. lbs. (36 Nm).
    NOTE
    Make sure the brake line is properly routed with loop to the rear and that the hose is not twisted.

  14.  
  15. Install the brake hose using 2 new copper washers. Torque the fitting bolt to 36 ft. lbs. (49 Nm).
  16.  
  17. Properly bleed the hydraulic brake system.
  18.  
  19. Install the wheel and tire assembly.
  20.  


CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Use a turkey baster or similar device to remove fluid from the master cylinder until it is about 1 / 2 full.
  4.  
  5. Remove or disconnect the following:

    Front wheel. Hand-tighten the lug nuts on the studs to prevent the rotor from falling off.
     

  6.  
  7. Install a C-clamp over the body of the caliper with the clamp ends against the rear of the caliper body and against the outboard pad. Tighten the clamp until the caliper piston is compressed enough to allow the caliper to be removed.

    Brake hose from the caliper and discard the 2 copper washers. Plug the openings to prevent system contamination or excessive fluid loss.
     
    Caliper bolts
     
    Caliper from the bracket
     
    Pin boots from the caliper support and inspect for damage
     

  8.  

To install:

  1. Install or connect the following:

    Brake pads and clips to the caliper bracket, if removed
     

  2.  
  3. Lubricate the pin boots and guide pins with silicone grease.
    NOTE
    Make sure the brake line is properly routed with loop to the rear and that the hose is not twisted.



    Pin boots, if removed
     
    Caliper onto the bracket and over the brake pads
     
    Caliper bolts through the caliper and torque to 27 ft. lbs. (34 Nm)
     



    Brake hose using 2 new copper washers. Torque the fitting bolt to 35 ft. lbs. (50 Nm).
     

  4.  
  5. Properly bleed the hydraulic brake system.

    Wheel
     

  6.  

  1. Remove the front wheel and tire assembly.
  2.  
  3. Disconnect the brake hose from the caliper and discard the 2 copper washers.
  4.  
  5. Plug the openings to prevent system contamination or excessive fluid loss.
  6.  
  7. Remove the lock pin and guide pin from the caliper.
  8.  
  9. Remove the caliper from the support, being careful not to damage the pin boots.
  10.  
  11. Remove the pin boots from the caliper support and inspect for damage.
  12.  

To install:

  1. If necessary, bottom the caliper piston by hand, or by using a C-clamp.
  2.  
  3. If removed, install the brake pads and clips to the caliper support.
  4.  
  5. Lubricate the pin boots and guide pins with silicone grease.
  6.  
  7. Install the pin boots into the caliper support, using the pin to assure that the boot passes all the way through the support.
  8.  
  9. Position the caliper onto the support and over the brake pads.
  10.  
  11. Lubricate the non-threaded portion of the guide and lock pins with silicone grease.
  12.  
  13. Install the pins through the caliper and torque to 27 ft. lbs. (36 Nm).
    NOTE
    Make sure the brake line is properly routed with loop to the rear and that the hose is not twisted.

  14.  
  15. Install the brake hose using 2 new copper washers. Torque the fitting bolt to 36 ft. lbs. (49 Nm).
  16.  
  17. Properly bleed the hydraulic brake system.
  18.  
  19. Install the wheel and tire assembly.
  20.  

  1. Remove or disconnect the following:

    Front wheel. Hand-tighten the lug nuts on the studs to prevent the rotor from falling off.
     

  2.  
  3. Install a C-clamp over the body of the caliper with the clamp ends against the rear of the caliper body and against the outboard pad. Tighten the clamp until the caliper piston is compressed enough to allow the caliper to be removed.

    Brake hose from the caliper and discard the 2 copper washers. Plug the openings to prevent system contamination or excessive fluid loss.
     
    Caliper bolts
     
    Caliper from the bracket
     
    Pin boots from the caliper support and inspect for damage
     

  4.  

To install:

  1. Install or connect the following:

    Brake pads and clips to the caliper bracket, if removed
     

  2.  
  3. Lubricate the pin boots and guide pins with silicone grease.
    NOTE
    Make sure the brake line is properly routed with loop to the rear and that the hose is not twisted.



    Pin boots, if removed
     
    Caliper onto the bracket and over the brake pads
     
    Caliper bolts through the caliper and torque to 27 ft. lbs. (34 Nm)
     



    Brake hose using 2 new copper washers. Torque the fitting bolt to 35 ft. lbs. (50 Nm).
     

  4.  
  5. Properly bleed the hydraulic brake system.

    Wheel
     

  6.  

 
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